Method of forming cast articles



G. W. BUNGAY.

METHOD 0F FORMING CAST ARTIVCLES.

v APPLICATION FILED MAR-W6, 192|.

Patented Dec. l2, 1922,A

Patented lDec. '12, 1922.

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STATES PATENT ortica.

GEORGE WALDEMAR BUNGAY, OF BROOKLYN, NEW YORK, ASSIGNOR, BY MESNE ASSIGNMENTS, TO ALUMINUM DIE-CASTING CORPORATION, OF GARWOOID, NEW JERSEY, A CORPORATION OF NEW JERSEY.

METHOD OF FORMIN G CAST ARTICLES.

Application filed March 16, 1921.

To all whom t may concern:

Be it known that I, GEORGE VVALDEMAR BUNGAY, a citizen of the United States, and a resident of the borough of Brooklyn, county of Kings, and State of New York, have invented certain new and useful Improvements in Methods of Forming Cast Articles, of which the following is a specification.

This invention relates broadly to the art of metal working and specifically to. a method of forming metallic articles having distorted or restricted passages or openings.

Vhile the art of what is known as die casting, a comparatively recent development in the art of metal working has come quite generally into use and has greatly supplanted the former methods of casting in which sand molds or their equivalents are used to receive the molten metal poured therein and allowed to cool, it has nevertheless been restricted in its field of application by reason of the fact that it has been found impossible to provide a means by which 'dilicult coring operations may be practically carried out. termed a diliicult coring operation may be found in an article suchas a vacuum cleaner nozzle in which the entrance end of the nozzle is required as having an elongatedrestricted passage which would necessarily prevent the removal of a core, in practical die casting methods, from the inlet end of the nozzle.

So it is with many articles which would lend themselves naturally to the die cast* ing methods, because of the relatively low cost of production arising by the use of such method, if it were not for the diliicult coring operations which render the die casting of such articles practically imposslble,

thus restricting the field of general appli-Y cation of die casting apparatus and -methods involving the usel of such.

"The method which I yemploy consists *in first die casting an article of approximately the shape required in its-finished state and of such a shape 'as to permit theA metallic cores used in die casting practice to be .removed from the article and then lsubjecting the article to pressure in order to distort it, giving it the required shape in its finished State.

A specific example of what is.

Serial No. 452,696.

treatment other than to remove the bursl formed at the union of the dies 'when a twopieced die isused.; the only other operation necessary to complete the article being the bending or distorting of the metal.

Another distinct advantage in employing my method resides in the fact that, by forming the unrestricted passages and later restricting them, I am enabled to use the cores of the die casting machine a great number of times, they being removed as a unit, whereas in forming restricted passages'by means of sand cores, the cores in order to be removed are necessarily destroyed.

The primary object of my invention is to provide a method wherein the process of what is known as die casting as practiced in the casting of articles having relieved or regularly shaped passages may be utilized to a practical extent in the Imanufacture of articles having restricted or torsional passages heretofore rendering impractical the formation of such articles by die casting methods.

facture of which I am enabled to practice my' invention to advantage; Figure 1 is a view in elevation of a vacuum cleaner nozzle viewed in the direction of the arrow shown in Figure 2, the mouth of the nozzle being shown as distorted,and

Figure 2 is a sectional View taken on line Q-Qfof Figure l, the mouth of the nozzle being shown as restricted. F or the purpose of illustrating how l propose to employ the method wherein the art of die casting articles having relieved or regularly shaped passages may be utilized to a practical degree in the manufacture of articles having restricted or torsional passages, l have elected to Show as such an article a vacuum cleaner nozzle, indicated as formed therein which is tapered to conform` to the general outline or contour of the main body longitudinally thereof as shown by the numeral 9 of Figure 1 and to the general contour of the body transversely thereof as clearly shown in Figure 2. The passage 8,'

it will be seen,l therefore gradually changes from a substantially true cylindrical passage, within the outlet end 7, to an elongated intake passage 10 as it approaches the elongated intake end 11 of the nozzle and gradually widens transversely 4thereof from.

a relatively narrow passage at the sides 12 of the nozzle towards the center 'of the nozzle or the plane thereof on which Figure i2 is taken.` Thus it becomes apparent that the passage within areas indicated by thecharacters A' and B gradually widens from any point therein towards the intake end of the passage 10 and in considering Figure 1 in connection with Figure 2 it further becomes apparent that the distance between the walls of the passage lying withiu the area C remains substantially uniform. Because of this construction I am enabled to cast the article in the form indicated by the full lines in Figure 1 by the use ofidie lasting methods with great rapidity, requiring the use of only two so-called' simple cores, one being used to form the outlet passage 8 and the other being used to form .the passage 10. The cores which are used t`o form the hollow body `are broughtl together in an end to end relation, meeting substantially -on the plane C-C of Figure 2, the outlet and inlet passage-forming cores being easily removed respectively' from the body upon the completion of the casting operation through the outlet and intake passages 8 and 10. a

In some instances it has been found desirable to restrict the intake passage at the entrance thereof to provide a relatively narrow elongated slot as shown at 13 which is somewhat narrowenat its 'center than at its extreme ends, its width heilig gradually increased towards itsl ends, as shown in Figure 1, to more evenly distribute the power of suction throughoutits length. To form such a passage, so restricted with respect to the interior of the nozzle, as shown more clearly in Figure Q, is practically impossible in forming the article as a completed unit -by die casting methods; and to convert the relatively simple die casting hereinbefore described into a finished casting, having such a restriction as required which would render the die casting of the completed article impossible, Ipropose to place the article in its form indicated in full lines of Figure 1 into a suitable die press and then shape the same to the required form. In so shaping the article the metal of the nozzle is moved from its full line position shown in Figure 1 to the dotted line osition shown therein, or from its dotted line position shown in Figure 2, to the full line position therein, thus forming the elongated slot 13 as required in an article in which it has heretofore been deemed impossible to' employ die casting methods to any extent whatsoever.

In the manufacture of vacuum cleaner nozzles of the type herein shown and described, it has been customary to cast the main body portion by die casting methods, and by the same methods cast a restricted entrance end adapted to be'secured to the main body in the completed article. ,This resulted in the necessity of two casting operations, and further necessitated expense and labor' in the assembly of the articles whereas I am enabled to accomplish the same result with one casting operation, and to eliminate the expense of assembly' by forming the article in a single piece in the first instance. lVhile it is true th t I resort to a pressing operation to distort the approximated article into its finished form, I am nevertheless enabled to produce the article at a lower cost than previously made possible, and Iam also enabled to produce amore desirable article, such as a vacuum cleaner nozzle, by reason of the fact that I overcome the objection to the two-piece nozzles in that they are sueceptible to leakage at the jointure of the two parts, which results in a detriment to theefiiciency of the cleaner in its operation.

Having thus described my invention, I claim;

f 1. The method of forming a, metallic article which consists in forming a die cast-- ing of such article to approximately its desired-form, and then distorting the casting to produce the finished article.

2. 'Ihe method of forming a; metallic article which consists in forminga die casting of suchiarticle to'approximately its desired form, and then subjecting the casting to pressure whereby the same is` distorted to produce the finished article.y i'

rIhe methodfof-forming a metallic article requiring a restricted passage which consists in forming a die casting of an approximated articlel having a passage cored therein, vand then distorting the approximated article to restrict the passage.

4. rl`he method of forming a metallic article having a passage therein, the entrance to which 1s required as being restricted which consists in forming a die casting of an article with an unrestricted passage therein, and then distorting the casting to .restrict the entrance tothe passage thereof.

The method of forming a metallic article required as having a uniform passage lessees `blended into a passage, one axis of which is' elongated with. respect to another axis thereof, the blended passage being restricted Aat one end thereof, which consists in diecasting a metallic article with an unrestricted blended passage, and .then partially closing the unrestricted passage to form a restriction therein. v

6. The method of forming a vacuum cleaner nozzle required as having a restricted inlet passage which consistsV in forming a die casting of an approximate article having an unrestricted inlet passage cored therein, and then subjecting the casting to pressure, whereby the vmetal surrounding the4 unrestricted passage is-moved and set to restrict the inlet passage.

7. The method of forming a vacuum cleaner nozzle required ashaving an inlet passage terminating in an elongated slot, which consists in die casting a metallic body having a passage cored therein, and then subjecting the body to pressure whereby. the

passage is partially closed lto provide `the elongated slot. n l

8. rihe method of forming a Vacuum cleaner nozzle required as having a passage terminating in a slot having a variable Width, which consists in die casting a metallic body having a passage cored therein, and then partially closing the passage to variable limits .to provide the slot having a variable width.

9. The method of forming a hollow metal article which consists in die casting the article so that a portion of the casting is in its permanent shape and pressing the other portion into the form desired in the finished article. j f g 10. rlhe method of forming a metallic ing, and then distorting the castinglto the shape desired in the finished article.

article which consists in forming a die cast- 

